Packaging containers and associated container blanks and packaging methods

ABSTRACT

A packaging container ( 100 ) configurable between at least a loading configuration and a flattened configuration, the packaging container including a front wall major panel ( 110 ) and a rear wall major panel ( 130 ) connected to the front wall major panel, wherein the front wall major panel and the rear wall major panel define four side walls ( 122, 124, 142, 144 ) when the packaging container is in the loading configuration, and wherein the front wall major panel and the rear wall major panel define two side walls when the packaging container is in the flattened configuration.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 62/981,912 filed Feb. 26, 2020, the disclosure of which is herein incorporated by reference in its entirety.

FIELD

The present patent application relates to product packaging and shipping, and, more particularly, to packaging containers that are configurable as a box during loading of product into the packaging container and then are reconfigurable as a flat/envelope for purposes of shipping.

BACKGROUND

With the advent of ecommerce, consumers have grown accustomed to purchasing various products over the internet or by other electronic means (e.g., email, facsimile or the like). A wide variety of products now move through ecommerce, including various consumer goods (e.g., razor blades, skin care products, and the like). Such products are typically shipped, whether by the Postal Service or by private courier, directly to consumers.

Manufacturers and distributors engaged in ecommerce continue to look for ways to improve packaging and shipping efficiency, as well as to reduce overall costs. Parcels (e.g., corrugated boxes) are attractive options for shipping consumer goods because they are durable, they can contain relatively large volumes, and they are relatively easy to load using an automated process (e.g., a pick-and-place robot). However, relatively speaking, parcels incur the highest shipping costs.

Flats (e.g., large envelopes) are an attractive alternative to parcels due to the relatively lower shipping cost associated with flats as compared to parcels. However, flats can be difficult to load, particularly when using an automated process (e.g., a pick-and-place robot) to load product into the flat.

Accordingly, those skilled in the art continue with research and development efforts in the field of product packaging and shipping.

SUMMARY

Disclosed are packaging containers.

In one example, the disclosed packaging container is configurable between at least a loading configuration and a flattened configuration, the packaging container including a front wall major panel and a rear wall major panel connected to the front wall major panel, wherein the front wall major panel and the rear wall major panel define four side walls when the packaging container is in the loading configuration, and wherein the front wall major panel and the rear wall major panel define two side walls when the packaging container is in the flattened configuration.

In another example, the disclosed packaging container includes a front wall major panel including a front wall first minor panel connected to a front wall second minor panel along a front wall preformed weakness, a rear wall major panel connected to the front wall major panel to at least partially define an internal volume therebetween, the rear wall major panel including a rear wall first minor panel connected to a rear wall second minor panel along a rear wall preformed weakness, and a closure flap connected to the rear wall major panel, the closure flap including a closure flap first minor panel connected to a closure flap second minor panel along a closure flap preformed weakness, wherein the closure flap preformed weakness is substantially aligned with the rear wall preformed weakness.

Also disclosed are container blanks for assembling the disclosed packaging containers.

Also disclosed are methods for packaging product in a packaging container.

In one example, the disclosed method for packaging a product in a packaging container includes steps of (1) configuring the packaging container into a loading configuration, wherein a front wall major panel and a rear wall major panel of the packaging container define four side walls when the packaging container is in the loading configuration, (2) inserting the product into the packaging container while the packaging container is in the loading configuration, and (3) after the inserting, configuring the packaging container into a flattened configuration, wherein the front wall major panel and the rear wall major panel define two side walls when the packaging container is in the flattened configuration.

Other examples of the disclosed packaging containers and associated container blanks and packaging methods will become apparent from the following detailed description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of one example of the disclosed packaging container, shown in a flattened and closed configuration;

FIG. 2 is a rear perspective view of the packaging container of FIG. 1 ;

FIG. 3 is a front perspective view of the packaging container of FIG. 1 , but shown in a flattened yet unclosed configuration;

FIG. 4 is a front and end perspective view of the packaging container of FIG. 1 , but shown in a loading configuration;

FIG. 5 is a front and end perspective view of the packaging container of FIG. 4 loaded with product and reconfigured to the flattened yet unclosed configuration shown in FIG. 3 ;

FIG. 6 is a plan view of one example of a blank that may be used to manufacture the packaging container shown in FIGS. 1-4 ; and

FIG. 7 is a plan view of another example of a blank that may be used to manufacture a packaging container similar to the packaging container shown in FIGS. 1-4 .

DETAILED DESCRIPTION

Disclosed are packaging containers that are reconfigurable to facilitate packaging and shipping efficiency at reduced cost. Specifically, the disclosed packaging container may be easily loaded with product (e.g., by an automated process, such as a pick-and-place robot) when the packaging container is in a loading configuration (see FIG. 4 ). Then, once loaded with product, the packaging container may be reconfigured to a flattened yet unclosed configuration (see FIGS. 3 and 5 ) and, ultimately, to a flattened and closed (e.g., sealed) configuration (see FIGS. 1 and 2 ).

Referring to FIGS. 1 and 2 , one example of the disclosed packaging container, generally designated 100, is shown in a flattened and closed configuration. The packaging container 100 includes a front wall major panel 110 (FIG. 1 ), a rear wall major panel 130 (FIG. 2 ), an upper closure flap 150, and a lower closure flap 170.

As shown in FIG. 1 , the front wall major panel 110 may be generally rectangular and may be defined by an upper edge 112, a lower edge 114, a first (left) side edge 116, and a second (right) side edge 118. As best shown in FIG. 3 , the upper edge 112 may be a free edge and the lower edge 114 may be a free edge. Using a front wall major panel 110 that is not generally rectangular is also contemplated and will not result in a departure from the scope of the present disclosure.

The front wall major panel 110 may include a front wall first minor panel 122 and a front wall second minor panel 124. The front wall first minor panel 122 may be connected to the front wall second minor panel 124 along a front wall preformed weakness 126. The front wall preformed weakness 126 may be formed using various weakening techniques, such as scoring, creasing, perforating or the like. Therefore, the front wall first minor panel 122 may bend (e.g., hinge) relative to the front wall second minor panel 124 along the front wall preformed weakness 126.

The front wall preformed weakness 126 may extend along the front wall major panel 110 from proximate (at or near) the upper edge 112 to proximate the lower edge 114. For example, the front wall preformed weakness 126 may extend from the upper edge 112 to the lower edge 114 as a substantially straight line that is substantially parallel with the first (left) side edge 116 of the front wall major panel 110.

At this point, those skilled in the art will appreciate that the front wall preformed weakness 126 may facilitate controlled bending of the front wall first minor panel 122 relative to the front wall second minor panel 124. Therefore, when a bending force is applied to the front wall first minor panel 122 and/or the front wall second minor panel 124, bending occurs primarily along the front wall preformed weakness 126.

As shown in FIG. 2 , the rear wall major panel 130 may be generally rectangular and may be defined by an upper edge 132, a lower edge 134, a first (left) side edge 136, and a second (right) side edge 138. Using a rear wall major panel 130 that is not generally rectangular is also contemplated and will not result in a departure from the scope of the present disclosure.

The rear wall major panel 130 may include a rear wall first minor panel 142 and a rear wall second minor panel 144. The rear wall first minor panel 142 may be connected to the rear wall second minor panel 144 along a rear wall preformed weakness 146. The rear wall preformed weakness 146 may be formed using various weakening techniques, such as scoring, creasing, perforating or the like. Therefore, the rear wall first minor panel 142 may bend (e.g., hinge) relative to the rear wall second minor panel 144 along the rear wall preformed weakness 146.

The rear wall preformed weakness 146 may extend along the rear wall major panel 130 from proximate the upper edge 132 to proximate the lower edge 134. For example, the rear wall preformed weakness 146 may extend from the upper edge 132 to the lower edge 134 as a substantially straight line that is substantially parallel with the first (left) side edge 136 of the rear wall major panel 130.

At this point, those skilled in the art will appreciate that the rear wall preformed weakness 146 may facilitate controlled bending of the rear wall first minor panel 142 relative to the rear wall second minor panel 144. Therefore, when a bending force is applied to the rear wall first minor panel 142 and/or the rear wall second minor panel 144, bending occurs primarily along the rear wall preformed weakness 146.

As shown in FIGS. 1-3 , the front wall major panel 110 may be connected to the rear wall major panel 130, such as by way of a sealing flap (e.g., sealing flap 210 shown in FIG. 6 or sealing flap 310 shown in FIG. 7 ). For example, the first (left) side edge 116 of the front wall major panel 110 may be aligned with the first (left) side edge 136 of the rear wall major panel 130, while the second (right) side edge 118 of the front wall major panel 110 may be alighted with the second (right) side edge 138 of the rear wall major panel 130.

Thus, as best shown in FIGS. 3 and 4 , an internal volume 102 may be defined between the front wall major panel 110 and the rear wall major panel 130. The upper edge 112 of the front wall major panel 110 and the upper edge 132 of the rear wall major panel 130 may define a first (upper) opening 104 into the internal volume 102. The lower edge 114 of the front wall major panel 110 and the lower edge 134 of the rear wall major panel 130 may define a second (lower) opening 106 into the internal volume 102.

Referring now to FIGS. 1 and 3 , the upper closure flap 150 may be connected to the rear wall major panel 130 along the upper edge 132 of the rear wall major panel 130. The upper edge 132 of the rear wall major panel 130 may include a preformed weakness, such as a score, a crease, perforations or the like, to facilitate controlled bending of the upper closure flap 150 relative to the rear wall major panel 130 along the upper edge 132 when reconfiguring the upper closure flap 150 from the unclosed configuration shown in FIG. 3 to the closed configuration shown in FIG. 1 .

At this point, those skilled in the art will appreciate that the first (upper) opening 104 into the internal volume 102 may be sealed (at least partially, if not fully), as shown in FIG. 1 , by bending the upper closure flap 150 relative to the rear wall major panel 130 and securing (e.g., with adhesive or by heat sealing) the upper closure flap 150 against the front wall major panel 110 (e.g., against both the front wall first minor panel 122 and the front wall second minor panel 124).

The upper closure flap 150 may include an upper closure flap first minor panel 152 and an upper closure flap second minor panel 154. The upper closure flap first minor panel 152 may be connected to the upper closure flap second minor panel 154 along an upper closure flap preformed weakness 156. The upper closure flap preformed weakness 156 may be formed using various weakening techniques, such as scoring, creasing, perforating or the like. Therefore, the upper closure flap first minor panel 152 may bend (e.g., hinge) relative to the upper closure flap second minor panel 154 along the upper closure flap preformed weakness 156.

The upper closure flap preformed weakness 156 may extend along the upper closure flap 150 from proximate the upper edge 132 of the rear wall major panel 130 to proximate the free edge 158 of the upper closure flap 150. Furthermore, the upper closure flap preformed weakness 156 may be substantially aligned with the rear wall preformed weakness 146 (FIG. 2 ) of the rear wall major panel 130. For example, the upper closure flap preformed weakness 156 and the rear wall preformed weakness 146 may be colinear.

Still referring to FIGS. 1 and 3 , the lower closure flap 170 may be connected to the rear wall major panel 130 along the lower edge 134 of the rear wall major panel 130. The lower edge 134 of the rear wall major panel 130 may include a preformed weakness, such as a score, a crease, perforations or the like, to facilitate controlled bending of the lower closure flap 170 relative to the rear wall major panel 130 along the lower edge 134 when reconfiguring the lower closure flap 170 from the unclosed configuration shown in FIG. 3 to the closed configuration shown in FIG. 1 .

At this point, those skilled in the art will appreciate that the second (lower) opening 106 into the internal volume 102 may be sealed (at least partially, if not fully), as shown in FIG. 1 , by bending the lower closure flap 170 relative to the rear wall major panel 130 and securing (e.g., with adhesive or by heat sealing) the lower closure flap 170 against the front wall major panel 110 (e.g., against both the front wall first minor panel 122 and the front wall second minor panel 124).

The lower closure flap 170 may include a lower closure flap first minor panel 172 and a lower closure flap second minor panel 174. The lower closure flap first minor panel 172 may be connected to the lower closure flap second minor panel 174 along a lower closure flap preformed weakness 176. The lower closure flap preformed weakness 176 may be formed using various weakening techniques, such as scoring, creasing, perforating or the like. Therefore, the lower closure flap first minor panel 172 may bend (e.g., hinge) relative to the lower closure flap second minor panel 174 along the lower closure flap preformed weakness 176.

The lower closure flap preformed weakness 176 may extend along the lower closure flap 170 from proximate the lower edge 134 of the rear wall major panel 130 to proximate the free edge 178 of the lower closure flap 170. Furthermore, the lower closure flap preformed weakness 176 may be substantially aligned with the rear wall preformed weakness 146 (FIG. 2 ) of the rear wall major panel 130. For example, the lower closure flap preformed weakness 176 and the rear wall preformed weakness 146 may be colinear.

Thus, as shown in FIGS. 1-3 , the disclosed packaging container 100 may be configurable as a flat/envelope. Specifically, as shown in FIG. 3 , the packaging container 100 may be in a flattened yet unclosed configuration prior to the upper closure flap 150 and the lower closure flap 170 being secured to the front wall major panel 110. Then, once the upper closure flap 150 and the lower closure flap 170 are secured to the front wall major panel 110, the packaging container 100 may be in a flattened and closed configuration, as shown in FIGS. 1 and 2 .

Prior to configuring the packaging container 100 as a flat/envelope, particularly prior to configuring to the flattened and closed configuration shown in FIGS. 1 and 2 , the packaging container 100 may be in the loading configuration shown in FIG. 4 . Configuring the packaging container 100 in the loading configuration shown in FIG. 4 may facilitate loading product 10 (FIG. 5 ) into the internal volume 102 of the packaging container 100, particularly when the loading is performed by an automated process, such as a pick-and-place robot.

To configure the packaging container 100 to the loading configuration shown in FIG. 4 from the flattened yet unclosed configuration shown in FIG. 3 , the front wall major panel 110 may be bent along the front wall preformed weakness 126 and the rear wall major panel 130 may be bent along the rear wall preformed weakness 146. Bending also may occur along the first (left) side edges 116, 136 and the second (right) side edges 118, 138. Furthermore, since the upper closure flap 150 and the lower closure flap 170 may both be connected to the rear wall major panel 130, bending the rear wall major panel 130 along the rear wall preformed weakness 146 may also require bending the upper closure flap 150 along the upper closure flap preformed weakness 156 and bending the lower closure flap 170 along the lower closure flap preformed weakness 176.

Thus, in the loading configuration shown in FIG. 4 , the packaging container 100 may become parcel or box-like to facilitate loading product 10 (FIG. 5 ) therein. Specifically, in the loading configuration, the packaging container 100 may temporarily present four side walls: the front wall first minor panel 122 of the front wall major panel 110 may serve as a first (front) side wall 180; the front wall second minor panel 124 of the front wall major panel 110 may serve as a second (left) side wall 182; the rear wall first minor panel 142 of the rear wall major panel 130 may serve as a third (rear) wall 184; and the rear wall second minor panel 144 of the rear wall major panel 130 may serve as a fourth (right) side wall 186.

Once product 10 (FIG. 5 ) has been loaded, as desired, into the internal volume 102 of the packaging container 100 while the packaging container 100 is in the loading configuration (FIG. 4 ), the packaging container 100 may then be reconfigured to the flattened yet unclosed configuration shown in FIGS. 3 and 5 .

To configure the packaging container 100 to the flattened yet unclosed configuration shown in FIG. 3 from the loading configuration shown in FIG. 4 , the front wall major panel 110 may be bent along the front wall preformed weakness 126 and the rear wall major panel 130 may be bent along the rear wall preformed weakness 146, thereby substantially flattening the front wall major panel 110 and the rear wall major panel 130, respectively. Bending also may occur along the first (left) side edges 116, 136 and the second (right) side edges 118, 138. Furthermore, since the upper closure flap 150 and the lower closure flap 170 may both be connected to the rear wall major panel 130, bending the rear wall major panel 130 along the rear wall preformed weakness 146 may also require bending the upper closure flap 150 along the upper closure flap preformed weakness 156 and bending the lower closure flap 170 along the lower closure flap preformed weakness 176, thereby substantially flattening the upper closure flap 150 and the lower closure flap 170, respectively.

Thus, in the flattened configuration (e.g., the flattened yet unclosed configuration shown in FIG. 3 ), the packaging container 100 may become envelope-like to facilitate reduced shipping cost. Specifically, in the flattened configuration, the packaging container 100 may present two side walls: the front wall first minor panel 122 and the front wall second minor panel 124 of the front wall major panel 110 may serve as a first (front) side wall 181; and the rear wall first minor panel 142 and the rear wall second minor panel 144 of the rear wall major panel 130 may serve as a second (rear) side wall 183.

Referring to FIG. 4 , the packaging container 100 may include a partition 190 within the internal volume 102 defined by the front wall major panel 110 and the rear wall major panel 130. Plural partitions 190 are shown in FIG. 4 . Those skilled in the art will appreciate that the shapes and configurations of the partitions will be dictated by, among other possible factors, the shape and configuration of the product 10 (FIG. 5 ) intended to be packaged in the packaging container 100.

The partitions 190 shown in FIG. 4 extend from the front wall major panel 110 to the rear wall major panel 130 and are connected to both the front wall major panel 110 and the rear wall major panel 130. For example, each partition 190 includes a first portion 192 connected (e.g., with adhesive) to the front wall major panel 110 and a second portion 194 connected (e.g., with adhesive) to the rear wall major panel 130. However, various other constructions are also contemplated and, if adopted, will not result in a departure from the scope of the present disclosure. For example, a partition 190 may extend from the front wall major panel 110 toward the rear wall major panel 130 without necessarily connecting to the rear wall major panel 130.

The disclosed packaging container 100 may be assembled from a container blank, such as the container blank 200 shown in FIG. 6 .

The container blank 200 may be cut (e.g., die cut) from a sheet of stock material to define an outer periphery 202. In one particular construction, the stock material may be a cellulosic material, such as paperboard (e.g., solid bleached sulfate paperboard), which may have a printable coating (e.g., clay) on a first major surface thereof and a coated or uncoated second major surface. As one non-limiting example, the stock material may be 18 point CARRIERKOTE® paperboard, which is commercially available from WestRock Company of Atlanta, Ga.

The container blank 200 may include a plurality of preformed lines (e.g., folds, scores, creases, perforations or the like) that define the front wall major panel 110 (including the front wall first minor panel 122 and the front wall second minor panel 124), the rear wall major panel 130 (including the rear wall first minor panel 142 and the rear wall second minor panel 144), the upper closure flap 150 (including the upper closure flap first minor panel 152 and the upper closure flap second minor panel 154), and lower closure flap 170 (including the lower closure flap first minor panel 172 and the lower closure flap second minor panel 174). Additionally, the container blank 200 may include a sealing flap 210, which may facilitate connecting (e.g., with an adhesive) the front wall major panel 110 to the rear wall major panel 130. In addition to facilitating the connection between the front wall major panel 110 and the rear wall major panel 130, the sealing flap 210 may also define the partitions 190 (see FIG. 4 ).

FIG. 7 depicts another example of a container blank 300 that may be used to assemble the disclosed packaging container 100. The container blank 300 may include a plurality of preformed lines (e.g., folds, scores, creases, perforations or the like) that define the front wall major panel 110 (including the front wall first minor panel 122 and the front wall second minor panel 124), the rear wall major panel 130 (including the rear wall first minor panel 142 and the rear wall second minor panel 144), the upper closure flap 150 (including the upper closure flap first minor panel 152 and the upper closure flap second minor panel 154), and lower closure flap 170 (including the lower closure flap first minor panel 172 and the lower closure flap second minor panel 174). Additionally, the container blank 300 may include a sealing flap 310, which may facilitate connecting (e.g., with an adhesive) the front wall major panel 110 to the rear wall major panel 130. In addition to facilitating the connection between the front wall major panel 110 and the rear wall major panel 130, the sealing flap 310 may also define the partitions 190 (see FIG. 4 ).

Optionally, as shown in the FIG. 7 , various tear-away portions 320 may be included in the container blank 300. The tear-away portions 320 may be defined by perforations, zippering, or the like. Those skilled in the art will appreciate that the presence of tear-away portions 320 in the assembled packaging container 100 may facilitate accessing product 10 (FIG. 5 ) packaged in the packaging container 100.

Although various examples of the disclosed packaging containers and associated container blanks and packaging methods have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims. 

What is claimed is:
 1. A packaging container configurable between at least a loading configuration and a flattened configuration, the packaging container comprising a front wall major panel and a rear wall major panel connected to the front wall major panel, wherein the front wall major panel and the rear wall major panel define four side walls when the packaging container is in the loading configuration, and wherein the front wall major panel and the rear wall major panel define two side walls when the packaging container is in the flattened configuration.
 2. The packaging container of claim 1 further comprising an upper closure flap connected to the rear wall major panel and sealable against the front wall major panel.
 3. The packaging container of claim 3 further comprising a lower closure flap connected to the rear wall major panel and sealable against the front wall major panel.
 4. A packaging container comprising: a front wall major panel comprising a front wall first minor panel connected to a front wall second minor panel along a front wall preformed weakness; a rear wall major panel connected to the front wall major panel to at least partially define an internal volume therebetween, the rear wall major panel comprising a rear wall first minor panel connected to a rear wall second minor panel along a rear wall preformed weakness; and a closure flap connected to the rear wall major panel, the closure flap comprising a closure flap first minor panel connected to a closure flap second minor panel along a closure flap preformed weakness, wherein the closure flap preformed weakness is substantially aligned with the rear wall preformed weakness.
 5. The packaging container of claim 4 wherein the front wall preformed weakness comprises at least one of a score, a crease and a perforation.
 6. The packaging container of claim 4 wherein the rear wall preformed weakness comprises at least one of a score, a crease and a perforation.
 7. The packaging container of claim 4 wherein the closure flap preformed weakness comprises at least one of a score, a crease and a perforation.
 8. The packaging container of claim 4 wherein the closure flap is an upper closure flap, and further comprising a lower closure flap connected to the rear wall major panel, the lower closure flap comprising a lower closure flap first minor panel connected to a lower closure flap second minor panel along a lower closure flap preformed weakness, wherein the lower closure flap preformed weakness is substantially aligned with the rear wall preformed weakness.
 9. The packaging container of claim 8 wherein the lower closure flap preformed weakness is substantially aligned with the upper closure flap preformed weakness.
 10. The packaging container of claim 4 wherein the rear wall major panel and the front wall major panel define an opening into the internal volume, and wherein the closure flap at least partially seals the opening when the closure flap is secured to the front wall major panel.
 11. The packaging container of claim 4 configurable between at least a loading configuration and a flattened configuration.
 12. The packaging container of claim 11 wherein the front wall major panel and the rear wall major panel define four side walls when the packaging container is in the loading configuration, and wherein the front wall major panel and the rear wall major panel define two side walls when the packaging container is in the flattened configuration.
 13. The packaging container of claim 12 wherein the four side walls are defined by the front wall first minor panel, the front wall second minor panel, the rear wall first minor panel and the rear wall second minor panel, respectively.
 14. The packaging container of claim 12 wherein the two side walls comprise a first side wall and a second side wall, wherein the first side wall is defined by the front wall first minor panel and the front wall second minor panel, and wherein the second side wall is defined by the rear wall first minor panel and the rear wall second minor panel.
 15. The packaging container of claim 4 further comprising at least one partition received in the internal volume.
 16. The packaging container of claim 15 wherein the partition is connected to both the front wall major panel and the rear wall major panel.
 17. A container blank for assembling the packaging container of claim 1 or claim
 4. 18. The container blank of claim 17 comprising paperboard.
 19. The container blank of claim 17 comprising a sealing flap.
 20. The container blank of claim 17 comprising a tear-away portion.
 21. A method for packaging a product in a packaging container, the packaging container comprising a front wall major panel and a rear wall major panel connected to the front wall major panel, the method comprising: configuring the packaging container into a loading configuration, wherein the front wall major panel and the rear wall major panel define four side walls when the packaging container is in the loading configuration; inserting the product into the packaging container while the packaging container is in the loading configuration; and after the inserting, configuring the packaging container into a flattened configuration, wherein the front wall major panel and the rear wall major panel define two side walls when the packaging container is in the flattened configuration. 